Washed down fabric articles and process for making same

ABSTRACT

A washed down fabric article and a process for treating a fabric article for producing the washed or faded effect is disclosed. The process may include fixing a dye onto the fabric article, discharging a portion of the dye with non-abrasive tumbling elements that includes a bleaching agent. The process further comprises neutralizing the bleaching agent with a neutralizer, and stabilizing the final color of the fabric article.

FIELD OF INVENTION

The present application claims priority to and the benefit of Indian Patent Application No. 3489/MUM/2014, filed on Nov. 5, 2014, the entire disclosure of which is incorporated into this application. The present disclosure generally relates to fabric articles, and in particularly a process for treating fabric articles to create a “washed down” or faded effect, and washed down articles produced by such a process.

BACKGROUND OF INVENTION

Fabric fading is a process practiced in the textile industry to impart a worn appearance on the fabric, often referred to as a “washed down” effect. This is generally done in order to impart an aesthetic finish, and to enhance the visual appeal of the fabric. Historically, denims were the primary textile fabrics processed to achieve washed down effect. Today, however, fading is widely used by fashion designers on other garments such as cotton shirts and jackets.

Several methods can be used to impart a washed down effect. In most cases, fading involves tumbling or striking the garment repeatedly with abrasive materials. The abrasive materials abrade the fabric can be cause discoloration at the point of abrasion. Typical abrasive materials include pumice stones, natural or artificial sand, pieces of metal, hard plastic, a rigid block of material made of organic fibers covered by a resilient abrasive layer, or the like. Pumice stones, or lava rock, is porous and tends to abrade the garment upon contact during tumbling. Pumice, as well as other natural rocks used in fading processes break apart and tend to form sharp pieces which may tear the garment or cause damage to the interior surface of processing equipment. Further, pumice, as it deteriorates during processing, forms sand and small rock pieces which are not easily separable from the treated garments. In garments treated by pumices stones, sand remains in the seams, pockets and other closed areas. Other methods to produce the washed down effect use abrasive stones impregnated with bleaching agents.

Typical fading methods that use abrasive materials have drawbacks. The extent of abrasion imparted on the garment is difficult to control. This can lead to low process output and efficiency because a significant percentage of garments are subjected to too much abrasion and are ruined. Further, the process is harsh. Everything in the machine is abraded, including the metal buttons and rivets on the garment as well as the internal components of the machines. In some cases, the drum of the machine requires holes to remove the sand and broken rock pieces. Furthermore, sand in the garments is an undesirable by-product of a pumice-based process as it can be a skin irritant.

There is a trend in the industry to improve efficiency in fading processes.

The above information is presented as background information only to help the reader to understand the present disclosure. Applicants have made no determination and make no assertion as to whether any of the above might be applicable as Prior Art with regard to the present application.

OBJECT OF INVENTION

The principal object of the embodiments herein relates to a washed down fabric article.

Another object of the embodiments herein is to provide a process for treating a fabric article to create a “washed down” or faded effect.

Another object of the embodiments herein is to fix a modified reactive dye onto fibers of the fabric article.

Yet another object of the embodiments herein is to provide a washed down effect on fabric articles, such as rug, bath mat, towel, wash cloth, bath robe, blanket, and shower curtain.

Yet another object of the embodiments herein is to provide a process for producing washed down effect without damaging the fabric article.

Yet another object of the embodiments herein is to provide a process for producing washed down effect on the fabric article to enhance its visual appeal.

These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings.

SUMMARY

An embodiment of the disclosure is a washed down fabric article, referred to in this summary as “the article embodiment.” The washed down fabric articled includes a panel defining an outer edge and being formed from a textile material that includes at least cellulosic fibers and a dye component fixed to the cellulosic fibers. The dye component is a modified reactive dye. The panel includes a first area having a first color and a plurality of dye discharge areas. The dye discharge areas include discharged dye components, wherein each dye discharge area has a second color that is different from the first color so as create a washed down effect.

According to the article embodiment, the panel has a face and a back, wherein the discharged dye areas are disposed along at least one of the face and the back.

According to the article embodiment, the panel has a face and a back, wherein the discharged dye areas are disposed along the outer edge.

According to the article embodiment, the dye component is a modified reactive dye. The modified reactive dye includes a chromophore that breaks via oxidation.

According to the article embodiment, the cellulosic fibers include cotton fibers.

According to the article embodiment, the textile material is a woven fabric.

According to the article embodiment, the textile material is a terry fabric. The terry fabric can include a plurality of piles, each pile having a tip and a base, wherein the tip of the piles define at least one of the plurality of discharged dye areas.

Another embodiment of the present disclosure is a process for treating a fabric article, referred to in this summary as a “first process embodiment.” The first process embodiment includes placing a dyed fabric article into a tumbling chamber, the fabric article including a dye fixed thereto. The process also includes tumbling the dyed fabric article in the tumbling chamber with a plurality of non-abrasive tumbling elements and alkaline agent. The non-abrasive tumbling elements include a bleaching agent, such that, the tumbling elements and alkaline agent repeatedly strike the fabric article to selectively discharge a portion of the dye from the fabric to create a washed down effect on the fabric.

According to the first process embodiment, the dye component is a modified reactive dye. The embodiment, the modified reactive dye includes a chromophore that breaks via oxidation.

According to the first process embodiment, the non-abrasive tumbling elements include expanded polystyrene impregnated with the bleaching agent.

According to the first process embodiment, the bleaching agent is a chlorine based or a non-chorine based bleaching agent.

According to the first process embodiment, the tumbling elements have a cross-sectional dimension in a range from 2.0 mm to 20.0 mm.

The first process embodiment includes the step of washing the fabric in at least one wash cycle after the tumbling step.

The first process embodiment can include the step of neutralizing the bleaching agent with a neutralizer. The neutralizer is at least one of a detergent, oxalic acid, and sodium metabisulphite, and an anti-chlorine agent.

The first process embodiment can include the step of applying a composition to the fabric article in the at least one wash cycle. The composition includes at least one of a softener and a wicking agent.

The first process embodiment includes the step of combining the tumbling elements and the bleaching agent prior to the step of placing the fabric article in the tumbling chamber.

Another embodiment of the present disclosure is a process for treating a fabric article, referred to in this summary as a “second process embodiment.” The second process embodiment includes the step of fixing a modified reactive dye onto fibers of a fabric article. The second process embodiment tumbling the fabric article in the tumbling chamber with a plurality of non-abrasive tumbling elements and alkaline agent, the non-abrasive tumbling elements including a bleaching agent, wherein the tumbling elements and alkaline agent repeatedly strike the fabric article to selectively discharge a portion of the modified reactive dye from the fabric article. The second process embodiment also includes washing the fabric article in a composition including water and a neutralizer in at least one wash cycle so as to neutralize the bleaching agent, and stabilizing the color of the fabric article with a soaping agent.

In accordance with the second process embodiment, the dye component is a modified reactive dye. Furthermore, the modified reactive dye includes a chromophore that breaks via oxidation.

Furthermore, the non-abrasive tumbling elements include expanded polystyrene impregnated with a bleaching agent. The bleaching agent is a chlorine based agent or a non-chlorine based agent.

In accordance with the second process embodiment, the tumbling elements have a cross-sectional dimension in a range from 2.0 mm to 20.0 mm.

In accordance with the second process embodiment, the neutralizer is at least one of a detergent, oxalic acid, and sodium metabisulphite, and an anti-chlorine agent.

The second process embodiment can include the step of applying a composition to the fabric article in the at least one wash cycle, the composition including at least one of a softener and a wicking agent.

These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications can be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications can be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES

This invention is illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:

FIG. 1 illustrates a schematic of a dye component affixed to a fabric article according to an embodiment of the present disclosure;

FIG. 2 is a schematic of a fabric article illustrated in FIG. 1

FIG. 3 is a fabric article according to another embodiment of the present disclosure;

FIGS. 4A through 4C is a fabric article according to another embodiment of the present disclosure;

FIG. 5 is a process flow diagram illustrating a method for treating a fabric article to produce a washed down effect, according to the embodiments described herein; and

FIG. 6 is a process flow diagram illustrating an overall process for producing a washed down effect on a fabric article.

DETAILED DESCRIPTION OF INVENTION

The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. Also, the various embodiments described herein are not necessarily mutually exclusive, as some embodiments can be combined with one or more other embodiments to form new embodiments. The term “or” as used herein, refers to a non-exclusive or, unless otherwise indicated. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein can be practiced and to further enable those skilled in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

An embodiment of the present disclosure is a process for treating a fabric article to have a washed down or faded appearance using non-abrasive materials. The process may include placing a dyed fabric article into a tumbling chamber of a tumbling machine. Thereafter, the fabric article is tumbled with a plurality of non-abrasive tumbling elements and an alkaline agent, such as soda ash. The non-abrasive tumbling elements include a bleaching agent. During tumbling, the tumbling elements and alkaline agent repeatedly strike the fabric article to selectively discharge a portion of dye from the fabric article to create a washed down effect on the fabric. The methods as described herein limit damage to the fabric article compared to typical methods of inducing washed down effect or appearance.

FIG. 1 is a schematic representation of a dye component 10 affixed to fiber components of a fabric article 20 according to an embodiment of the present disclosure. The dye component 10 imparts color to the fabric article 20 through fixation to the fiber structure as known in the art. The dye component 10 is a modified reactive dye that includes a chromophore 12 bearing a functional group 16, and a reactive anchor 14 bound to the chromophore 12. The reactive anchor 14 is fixed to the fiber of the fabric article 20. The functional groups are usually salts of an acid, and ensure water solubility. The reactive anchor is bound to the chromophore by a chemical linkage. The purpose of the reactive anchor is to fix the chromophore on to the fabric article and ensure good wash fastness. An example of a reactive anchor may be vinyl sulphone. When the dyed fabric article is subsequently processed as described herein, the dye component undergoes discoloration to create the washed down effect in certain areas or zones on the garment. Specifically, the washed down fabric articles as described herein includes a first area having a first color and a plurality of dye discharge areas. The dye discharge areas include discharged dye components such that each dye discharge area has a second color that is different from the first color so as create a washed down effect. The discharged dyes areas are generally lighter in color than the first color of the remaining portions of the panel. The color difference is observable under a number of lighting sources, such as cool white, florescent, or other light sources used in the art to discern color differences.

The dye component 10 can be a modified reactive dye. A modified reactive dyes include a chromophore configured such that it is weakened or broken via an oxidation treatment. Oxidation changes the color of fabric article where the modified reactive dye has been exposed or subjected to the oxidation treatment. As discussed below, the oxidation treatment includes contacting the fabric article with the bleaching agent and alkaline agent. Without being bound by a particular theory, it is believed that the bleaching agent and alkaline agent in combination with the tumbling of the fabric with the tumbling elements induces aeration that aids in oxidation of modified reactive dye. The result is a lighter color in certain areas of the fabric article compared to other areas of the fabric article. An exemplary modified reactive dye is a dycon dye, available from the ColorBand Dyestuff Pty. Ltd.

When the dyed fabric article is subsequently processed as described herein, the dyed fabric article undergoes some discoloration in selective portions of the fabric to create the washed down effect. For instance, the tumbling elements strike the fabric article, which cause the discharge or diffusion of the dye in portions of the fabric article (see e.g. areas 70 in FIGS. 3 and 4A). The discharged portions of the dye creates a faded look. More specifically, as the tumbling elements strike the fabric article, the bleaching agent and alkaline agent initiates oxidation of the chromophore along portions that fabric that the tumbling element come in contact with. Repeated contact between the tumbling elements and fabric articles causes further oxidation and loss of color. Following stabilization of the dyes after tumbling, the modified reactive dyes provide good all-round color fastness to the fabric article, including light fastness, bleaching fastness, and washing fastness, and at the same time providing a washed down effect on the fabric article.

While a modified reactive dye has been found to produce desirable results, it is possible that other dye components could be used based on the fiber content of the fabric article. For instance, the dyes may be an acid dye, azoic dyes, basic dye, direct dye, disperse dye, reactive dye, sulphur dye, oxidation dye, mordant dye (chrome dye), optical / fluorescent brightener, solvent dye, vat dyes or any other dye or pigment used to impart color to the fabric article.

FIGS. 2 through 4C illustrate different types of fabric articles processed with the tumbling elements to produce a washed down affect as described herein. A washed down article or fabric article as used herein includes: A) a product made primarily from a textile material that includes edges or defined borders and are typically stitched, hemmed, or assembled into a final product configuration for shipment to the consumer or retailer; or B) the textile material itself. A textile material can include woven fabrics, knitted fabrics, and laminates thereof. Accordingly, the fabric article therefore includes piece goods, such as sheeting, rugs, bath mats, towels, wash cloths, bath robes, blankets, shower curtains, and the like. In addition, a fabric article includes wide goods of fabrics, such as wide woven fabrics, knitted fabrics, woven terry fabrics, non-woven fabrics, knitted terry fabrics, or laminates thereof. Accordingly, the process as described herein can be used on wide goods or pieced goods.

Textile materials described herein have a dye component that has been affixed to fibers according to a variety of dye systems and techniques. Accordingly, a dyed fabric article includes products formed from textile fabrics with color imparted into the fibers prior to fabric formation or after fabric formation. For example, a dyed fabric article includes textile materials formed with yarns that are dyed prior to fabric formation, such as a yarn dyed fabrics. A dyed fabric article includes textile materials that dyed using continuous or batch dying systems following fabric formation. In addition, a dyed fabric article also include cross-dyed fabrics, which are textile fabrics with two or more fiber types dyed to two or more shades of color using two or more different dye components and dye processes. Furthermore, the dyed fabric articles can include fabric article that have manufactured into fabrics, cut, sewn, or otherwise assembled into products such as rugs, sheeting and the like. In addition, dyed articles can be printed, include designs, or other visual features.

FIG. 2 illustrates a fabric article 20 illustrated as a woven fabric. The woven fabric has a plurality of warp yarns 30 and a plurality of weft yarns 40 interwoven with the plurality of warp yarns 30 to define the woven fabric 20. The woven fabric 20 includes face and a back opposite the face along a face-back direction 8 (into the page and not shown in FIG. 2). The warp yarns 30 extend along a warp or longitudinal direction 6 and the weft yarns extend along a weft direction 4 (or lateral or cross direction). The warp direction 6, weft direction 4, and face-back direction 8 are perpendicular with respect to each other. The plurality of weft yarns 40 are interwoven with the plurality of warp yarns 30 to define the woven fabric with any a number of different woven structures. Exemplary woven structures include, but are not limited to: plain weaves; basket weaves, rib weaves (e.g. 2×1 rib weave; 2×2 rib weave; or 3×1 rib weave) twill weaves; oxford weaves; and satins weaves (e.g. satin dobby base, satin stripe satin 5/1, satin 4/1 satin; 4/1 satin base strip; 4/1 stain swiss dot; 4/1 down jacquard; 5/1 satins). Other woven fabrics can be a terry woven fabric.

The warp yarns 30 and weft yarns 40 can be spun yarns. Spun yarns can be ring spun yarns, open end yarns, rotor spun yarns, vortex spun yarns, core spun yarns, jet spun yarns, or compact spun yarns. In another embodiment, the warp yarns can be Hygrocotton® brand yarns marketed by Welspun India Limited. Furthermore, yarns can be formed as disclosed in U.S. Pat. No. 8,833,075, entitled “Hygro Materials for Use in Making Yarns and Fabrics,” (the 075 patent). The 075 patent is incorporated by reference into present disclosure. The spun yarns can be formed from natural, staple fibers, synthetic fibers, or blends of natural and synthetic fibers. Natural fibers used to form the warp yarns include cotton, silk, linen, flax, bamboo, hemp, wool, and the like. Synthetic fibers include rayon fibers (e.g. Modal, Lyocell) or thermoplastic fibers, such as polyethylene terephthalate (PET) fiber, polylactic acid (PLA) fiber, polypropylene (PP) fibers, polyamide fibers, and microfiber staple fibers. In one example, the warp yarns and weft yarns are formed from cellulosic fibers.

As described above, the warp and weft yarns can also be continuous filament yarns formed from PET, PLA, PP, or polyamide polymers. The continuous filament yarns can also include bi-component filaments, such as PET and PP components.

In should be appreciated that the fabric article can also include knitted fabrics. For instance, both weft knitted fabrics or warp knitted fabrics can be use processed as described herein. In still other examples, the terry fabric can be a knitted terry fabric. Knitted fabrics can be formed with spun or continuous filament yarns as described above with respect to the woven fabric illustrated in FIG. 2. The knitted fabrics can include cellulosic fibers and the modified reactive dye component.

FIG. 3 illustrates a dyed fabric article, such as a rug 120, with a washed down effect, formed form the woven fabric 20 discussed above. The rug 120 includes a panel 116 with having a defined border or edge 130. As shown, the panel 116 includes a first end 122, a second end 124 spaced from the first end 122 along the warp direction 6, and opposed sides 126 and 128 spaced apart with respect to each other along weft direction 4. The edge 130 extends about ends 122, 124 and sides 126 and 128 to define a rectangular shape. However, the shape is not limited to a rectangle. The panel 116 can be square, circular, oval, or other shapes. As shown in FIG. 3, the article 120 includes a plurality of washed down areas or portions 70. The dye discharge areas 70 can be disposed along different locations of the edge 130. It should be appreciated that the process described herein can create washed-down or dye discharge areas along any portion of the panel 116. Further, the washed down areas could be small shaped areas distributed randomly along panel in both warp direction 6 and weft direction 4. In addition, the process as described herein may result in a faded look across an entirety of the panel 116 so that defined portions 70 may not be discernable.

FIGS. 4A through 4C illustrated illustrates a dyed fabric article configured as a terry towel 220. Common features between article 120 shown in FIG. 3 and terry towel shown in FIGS. 4A-4C will use same reference numbers. The terry towel 220 includes a woven ground component 240 and a pile component 250 that includes a plurality of piles that extends upwardly (or downwardly) from the ground component 240 along direction 8. The pile component 250 can include upper piles, lower piles, or both upper and lower piles. The piles may be loops or cut piles. The ground component 240 can include warp yarns and weft yarns, similar to those described above for woven fabric article 20. The pile component 250 can include pile yarns that define the piles. The warp, weft and pile yarns can be formed from spun yarns as described above. Furthermore, one or more of the warp, weft, and pile yarns could include continuous filament yarns. Thus, the ground component and pile component include natural fibers, such as cellulosic fibers, synthetic fibers, or blends of both natural and synthetic fibers. The terry fabric can be a woven terry fabric or a knitted terry fabric.

The towel 220 includes a panel 216 with having a defined border or edge 230. As shown, the panel 116 includes a first end 122, a second end 124 spaced from the first end 122 along the warp direction 6, and opposed sides 126 and 128 spaced apart with respect to each other along the weft direction 4. The edge 230 extends about ends 122, 124 and sides 126 and 128 to define a rectangular shaped towel. As shown in FIG. 3, the terry articles 220 includes a plurality of washed down zones or portions 70. The portions 70 are shown to illustrate how the dye is discharged from the terry article in one example. It should be appreciated that the process described herein can create washed down zones along any portion of the panel 116. Further, the washed down portions 70 could be small shaped areas distributed randomly along panel in both the warp direction 6 and weft direction 4. In addition, the process as described herein may result in a faded look across an entirety of the panel 216 so that defined portions 70 may not be discernable. As shown in FIG. 4C, the pile loops have an upper portion or tip 252 and a lower portion or base 254 adjacent to the ground component 240. During processing as described below, the tumbling elements cause the discharge of dye at the upper portion 252 of the piles so that the base 254 of the pile has a different color than the tip of the pile. Accordingly, the terry fabric includes a plurality of piles, each pile having a tip and a base, wherein the tip of the piles define at least one of the plurality of discharged dye areas such that the tip is lighter than the base.

FIG. 5 is a flow chart illustrating a method 300 for treating a fabric to produce a washed down or faded effect, according to an embodiments described herein. Step 302 includes producing a dyed fabric article. For instance, the fabric article can be woven or knit. In another example, such as for the article shown FIGS. 4A-4C, a terry towel can woven on a terry loom. In some instances, further manufacturing can be used cut and assemble the fabric article into piece goods can be further processed as discussed below. After the fabric article is manufactured a dye can be fixed to the fabric article at step 302. In an alternative embodiments, the fabric article may be formed with yarn-dyed yarns so that post-fabric formation dyeing is not necessary. Accordingly, the result of step 302 can include dyed fabrics articles as wide goods or dyed fabric articles as piece goods. In one example, the dyed fabric articles include a modified reactive dye chromophore that can be broken via oxidation process as described herein.

At step 304, the dyed fabric articles are tumbled with a plurality of non-abrasive tumbling elements. Exemplary non-abrasive tumbling elements can be expanded polystyrene granules. Step 304 may include the step of placing a dyed fabric article into a tumbling chamber of tumbling machine. A typical tumbling machine can be used that includes a tumbling chamber or drum and motor configured to rotate the tumbling chamber in both clockwise and counterclockwise directions. The tumbling chamber may be a stainless steel chamber or wooden tumbling chamber. Thereafter, the fabric article is tumbled with a plurality of non-abrasive tumbling elements and alkaline agent within the tumbling. During tumbling, the tumbling elements repeatedly strike the fabric article to selectively discharge a portion of the dye from the fabric to create a washed down effect on the fabric.

The non-abrasive tumbling elements include a bleaching agent and at least one salt. An exemplary non-abrasive tumbling element is expanded polystyrene granules (referred to as “thermocol”), wooden balls, or other polymeric elements that are smooth, lightweight and non-abrasive. It should be appreciated that any other non-abrasive materials may be used as tumbling elements in tumbling chamber. In one particular example, the tumbling elements are expanded polystyrene granules with a cross-sectional dimension between about 2 mm to about 20 mm. The expanded polystyrene granules may be spherical. However, other three-dimensional shapes are possible. Furthermore, each expanded polystyrene granules may have a low weight.

In an embodiment, the bleaching agent is combined with the tumbling elements in the tumbling chamber prior to adding the fabric articles to the chamber. The total amount of the tumbling elements used is based on the volume of tumbling chamber. In one example, one quarter of the tumbling chamber is filled with the tumbling elements. In one example, one half of the tumbling chamber is filled with the tumbling elements. In another example, three quarters of the tumbling chamber is filled with the tumbling elements. Regardless of the amount of tumbling elements loaded into the tumbling chamber, the bleaching agent is loaded into the chamber over the tumbling elements. The tumbling elements and bleaching agent is processed for a period of time so that the bleaching agent is adequately impregnated into or on the tumbling agents. In one example the period of time is about between 5 minutes to about 25 minutes. In one example, the tumbling chamber is run for about 10 minutes. The bleaching agent can be a chlorine based agent or a non-chlorine based agent. In one example, the bleaching agent is sodium hypochlorite. Other known bleaching agents can also be used, if desired.

As described above, the tumbling elements can further include at least one salt. The salt can be alkaline agent (or sodium carbonate) or calcium carbonate. The salt can be added onto the tumbling elements after the bleaching agent is added to the chamber and processed as described above. The non-abrasive material with the bleaching agent, and the tumbling chamber is again run for at least 5 mins up to 25 or more minutes as needed to ensure that the salt and the bleaching agent are combined with tumbling elements.

After the bleaching agent and salt is combined with the tumbling elements, the fabric articles can be loaded into the tumbling chamber for discharge of the dye from the fabric article in step 304. In an embodiment, the discharge is a selective discharge. The selective discharge is where the color on flat edge portions areas of the fabric article, like selvedges, borders, hem has effect of contrast of with the dyed color that creates a faded look. In examples where terry fabrics are processed, such as shown in FIGS. 4A-4C, the base of the pile loop has a different color than the tip of the pile loop. The tumbling step proceeds for a period of time. The tumbling step is preferably carried out at the room temperature and under atmospheric pressure. For instance, the tumbling chamber loaded with fabric articles is run for between 5-25 minutes to impart a faded look to the fabric articles. As described above non-abrasive tumbling elements can be light weight and do not acquire significant momentum due to rotational motion of the tumbling chamber. The tumbling elements can therefore “float” inside the tumbling chamber and contact the surface of the fabric article at a low velocity for a gentle contact with the fabric article. Because the movement of the tumbling elements inside the chamber is gentle, the effect observed on the fabric article is smooth not too drastic. Preferably, the tumbling process is checked periodically to observe the effect on the fabric article. For instance, over tumbling may have an adverse effect on the appearance of the fabric. Similarly, tumbling for less time may result in non-uniform fading.

At step 306, the bleaching agent is neutralized by washing the faded fabric article in a composition including water and a neutralizer for at least one wash cycle. The neutralizer is at least one of a detergent, oxalic acid, sodium metabisulphite, and an anti-chlorine agent. However, other neutralizing agents can be used if desired.

At step 308, the method 300 includes stabilizing the final color of the fabric by adding a soaping agent to the fabric article in the tumbling chamber to provide a washed down effect. In one example, the fabric is contacted with the soaping agent in the tumbling chamber for about 10 minutes. However, the stabilizing step can be shorter than 10 minutes or longer than 10 minutes as needed. This stabilizing step helps remove any unfix dye and to stabilize the final color of the fabric. Any soaping agent can be used. In one example, the soaping agent can be Periquest® available from Chemotex Co.

Following washing with the soaping agent, functional finishes, such as a softener and optionally a wicking agent, can be applied to the fabric article. Softening agents are used to improve the hand and tactile feel of the fabric. It should be appreciated that any softener can be used, such as a silicone based softener. In one example, the softener can be Rucofin®, available from the Rudolf Group. Wicking agents can also be added to the fabric article to help spread moisture to the fabric surface quickly aid in quick moisture evaporation. The process further includes drying the fabric article for a period of time and at predetermined temperature range. The period of time can be sufficient to adequately dry the fabric article. For instance, the time period can be in a range of 30-40 minutes. The temperature can be between 50° C. to 70° C., preferably about 60° C.

FIG. 6 is a block diagram illustrating an exemplary process for treating the fabric articles to create the washed down effect on the fabric. As noted above, a tumbling chamber of a standard size and dimension and is half filled with the tumbling elements at step 410. In step 414, a bleaching composition is added to the tumbling chamber. For instance, about 2.0 kilograms of a bleaching agent, such as a chlorine based agent or a non-chlorine based agent. In one example, the bleaching agent, such as sodium hypochlorite, (approximately 2 KG) is added the tumbling elements. Next, the tumbling chamber is run for a period of time, e.g. for 10-30 minutes, in both clockwise and counterclockwise directions to ensure that the tumbling elements have properly combined with the bleaching agent. Next, in step 418 the salt, such as sodium carbonate or calcium carbonate (e.g. approximately 250 grams to 1000 grams) can be added in the tumbling chamber. Again, the tumbling chamber the salt and tumbling elements, but without fabric articles, is run for period of time (e.g. between 5-30 minutes).

Next, in step 422 the fabric articles (approximately 8-10 piece goods depending on the size of the tumbling chamber) are loaded in the tumbling chamber and the tumbling chamber is run for 5 minutes up to 25 minutes or more. The fabric articles are checked periodically. When sufficient tumbling is completed, the fabric articles are removed from the tumbling machine.

Next, in step 428, the fabric articles are then placed in the washing machine. In step 432, the fabric articles are treated with the neutralizing agent, such as sodium metabisulphite, anti-chlorine agent or other as described herein. The neutralizing agent can be loaded into the washing machine in a composition between about 1 to 2 GPL and processed for between 5 to 25 minutes. Next, in step 440, a soaping agent at 1 GPL is added to the washing machine. The pH in the washing step following addition of the soaping agent should be between 6-6.5.

The fabric articles can be further treated in step 444 with a functional finish, with the softener and optionally a wicking agent. The composition is drained from the washing machine. Next, in step 448, the fabric articles are dried at 60° C. for about 30-40 minutes. It should be appreciated that the drying steps can utilize a higher temperature or lower temperate as needed. It should be noted draining is required after each step like neutralization, treatment with the soaping agent, the softener, and the wicking agent to remove the chemicals.

The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein. 

What is claimed is:
 1. A washed down fabric article, comprising: a panel defining an outer edge and being formed from a textile fabric that includes at least cellulosic fibers and a dye component fixed to the cellulosic fibers, the dye component including a modified reactive dye, the panel including a first area having a first color and a plurality of dye discharge areas, each dye discharge areas including discharged dye components, such that the dye discharges areas has a second color that is different than the first color so as to create a washed down effect.
 2. The washed down fabric article of claim 1, wherein the panel has a face and a back, wherein the discharged dye areas are disposed along at least one of the face and the back.
 3. The washed down fabric article of claim 1, wherein at least one of the discharge areas are disposed along the outer edge of the panel.
 4. The washed down fabric article as claimed in claim 1, wherein the textile fabric is a yarn dyed fabric.
 5. The washed down fabric article of claim 1, wherein the modified reactive dye includes a chromophore that breaks via oxidation.
 6. The washed down fabric article of claim 1, wherein the cellulosic fibers include cotton fibers.
 7. The washed down fabric article of claim 1, wherein the textile fabric is a woven fabric, non-woven fabric or a knit fabric.
 8. The washed down fabric article of claim 6, wherein the textile fabric is a woven fabric.
 9. The washed down fabric article of claim 6, wherein the woven fabric is a plain weave, a satin weave, a basket weave, a rib weave, a twill weave, oxford weave, or a terry woven fabric
 10. The washed down fabric article of claim 1, wherein the textile fabric is a terry fabric.
 11. The washed down fabric article of claim 9, wherein the terry fabric is a woven terry fabric or a knitted terry fabric.
 12. The washed down fabric article of claim 9, wherein terry fabric includes a plurality of piles, each pile having a tip and a base, wherein the tip of the piles define at least one of the plurality of discharged dye areas.
 13. The washed down fabric article as claimed in claim 1, includes one of rug, bath mat, towel, wash cloth, bath robe, blanket, and shower curtain.
 14. A process for treating a fabric article, the process comprising: placing a fabric article into a tumbling chamber, the fabric article including a dye component fixed thereto; and tumbling the dyed fabric article in the tumbling chamber with a plurality of non-abrasive tumbling elements and alkaline agent, the plurality of non-abrasive tumbling elements and the alkaline agent repeatedly strike the fabric article to selectively discharge a portion of the dye from the fabric article to create a washed down effect on the fabric article.
 15. The process according to claim 14, wherein the dye component is a modified reactive dye.
 16. The process according to claim 14, wherein the modified reactive dye includes a chromophore that breaks via oxidation during the tumbling step.
 17. The process according to claim 14, wherein the non-abrasive tumbling elements include expanded polystyrene impregnated with the bleaching agent.
 18. The process according to claim 15, wherein the bleaching agent is a chlorine based or a non-chorine based bleaching agent.
 19. The process according to claim 14, wherein the plurality of non-abrasive tumbling elements have a cross-sectional dimension in a range from 2.0 mm to 20.0 mm.
 20. The process according to claim 14, further comprising the step of washing the fabric in at least one wash cycle after the tumbling step.
 21. The process according to claim 20, wherein the at least one wash cycle comprising the step of neutralizing the bleaching agent with a neutralizer.
 22. The process according to claim 21, wherein the neutralizer is at least one of a detergent, oxalic acid, and sodium metabisulphite, and an anti-chlorine agent.
 23. The process according to claim 21, further comprising the step of applying a composition to the fabric article in the at least one wash cycle, the composition including at least one of a softener and a wicking agent.
 24. The process according to claim 14, further comprising the step of combining the plurality of non-abrasive tumbling elements and the bleaching agent prior to the step of placing the fabric article in the tumbling chamber.
 25. A process for treating a fabric article, the process comprising the steps of: fixing a modified reactive dye onto fibers of the fabric article; tumbling the fabric article in the tumbling chamber with a plurality of non-abrasive tumbling elements and alkaline agent, the non-abrasive tumbling elements including a bleaching agent, wherein the plurality of non-abrasive tumbling elements and alkaline agent repeatedly strike the fabric article to selectively discharge a portion of the modified reactive dye from the fabric article so as to define discharge dye portions; washing the fabric article in a composition including water and a neutralizer in at least one wash cycle so as to neutralize the bleaching agent; and stabilizing the modified reactive dye that remains on the fabric article with a soaping agent.
 26. The process according to claim 25, wherein the modified reactive dye includes a chromophore, wherein the tumbling step oxidizes the chromophore via at least the bleaching agent and the alkaline agent.
 27. The process according to claim 25, wherein the non-abrasive tumbling elements include expanded polystyrene impregnated with a bleaching agent.
 28. The process according to claim 25, wherein the bleaching agent is a chlorine based agent or a non-chlorine based agent.
 29. The process according to claim 25, wherein the tumbling elements have a cross-sectional dimension in a range from 2.0 mm to 20.0 mm.
 30. The process according to claim 25, wherein the neutralizer is at least one of a detergent, oxalic acid, and sodium metabisulphite, and an anti-chlorine agent.
 31. The process according to claim 25, further comprising the step of applying a composition to the fabric article in the at least one wash cycle, the composition including at least one of a softener and a wicking agent. 